Packing Material Having Microsphere Insulation Members That Expand Towards One Another

ABSTRACT

In one embodiment, a packaging material can be used to form a package such as a bag or a box. The material has a substrate and a plurality of insulation members, each having a body that is adhered to a surface of the substrate and each having a plurality of expandable microspheres. The bodies are a pattern such that the bodies are spaced apart from one another by gaps. The expandable microspheres expand in response to the application of energy such that the insulation members to expand towards one another to at least partially fill in the gaps. In another embodiment, the material has microspheres that are activated such that the insulation members include extensions that extend from their respective bodies towards one another to fill in the gaps.

BACKGROUND

A variety of packaging materials are commonly used for shipping items. For example, some common packaging materials include bubble wrap, thin film pillow packs, and Styrofoam. Typically these packaging materials are selected to provide a desired level of impact resistance and/or thermal resistance to protect the product being shipped from damage. However, these packaging materials typically are not curbside recyclable.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description will be better understood when read in conjunction with the appended drawings, in which there is shown in the drawings example embodiments for the purposes of illustration. It should be understood, however, that the present disclosure is not limited to the precise arrangements and instrumentalities shown. In the drawings:

FIG. 1 shows a top plan view of a packaging material according to one embodiment in an un-activated state and without a top layer;

FIG. 2 shows a cross-sectional view the packaging material of FIG. 1 at section 2-2 with a top layer;

FIG. 3 shows a cross-sectional view of the packaging material of FIG. 1 at section 3-3 with a top layer;

FIG. 4 shows an enlarged perspective view of one un-activated insulation member of FIG. 1 attached to a substrate;

FIG. 5 shows a top plan view of the packaging material of FIG. 1 according to one embodiment in an activated state and without a top layer;

FIG. 6 shows a cross-sectional view of the packaging material of FIG. 4 at section 6-6 with a top layer;

FIG. 7 shows a cross-sectional view of the packaging material of FIG. 4 at section 7-7 with a top layer;

FIG. 8 shows a perspective view of one activated insulation member of the packaging material of FIG. 4 attached to a substrate;

FIG. 9 shows a schematic diagram of a microsphere of the packaging material of FIGS. 1 to 8 in un-activated and activated states;

FIG. 10 shows a magnified view of the microspheres of FIGS. 1 to 8 in an unactivated state at 500 times magnification;

FIG. 10 shows a magnified view of the microspheres of FIGS. 1 to 8 in an activated state at 500 times magnification; and

FIG. 12 shows a bag according to one embodiment formed from the packaging material of FIGS. 1 to 8.

DETAILED DESCRIPTION

In one example embodiment, a packaging material 100 is shown that can be used to form packages such as bags, boxes, or other suitable packages for protecting products from impact and/or damage and provide thermal insulation. The packing assembly or material 100 is configured to transition from an un-activated or un-expanded state as illustrated in FIGS. 1 to 4 to an activated or expanded state as illustrated in FIGS. 5 to 8. In general, the packaging material 100 comprises a substrate 102 having an upper or first substrate surface 104. The packaging material 100 further comprises a plurality of insulation members 108, shown in the figures as strips, each having a body 125 that is adhered to the substrate surface 104, and each comprising a plurality of expandable microspheres 112 (see FIGS. 9 to 11). The bodies 125 are arranged on the substrate surface 104 in a pattern such that the bodies 125 are spaced apart from one another by gaps 110. The expandable microspheres 112 are configured to expand in response to application of energy such as heat such that the insulation members 108 expand towards one another to at least partially fill in the gaps 110. For example, the insulation members 108 can expand from the un-activated state in FIGS. 1 to 4 to the activated state in FIGS. 5 to 8. In this regard, a body 125 expands toward adjacent bodies 125 under the application of heat, which time and temperature relationship can be determined according to particular dimensions, chemistry, and like parameters of the bodies 125 and materials.

Referring specifically to FIGS. 1 to 4, the substrate 102 includes the first substrate surface 104 and a second substrate surface 106, opposite the first substrate surface 104 along a transverse direction T. The substrate 102 can be formed from a flexible and/or bendable material such as sheet of paper, cardboard, plastic, or any other suitable flexible and/or bendable packaging material. In some embodiments, as shown, the substrate 102 can have a planar configuration wherein the first and second substrate surfaces 104 and 106 are parallel to one another. Further, the substrate 102 can have a length along a longitudinal direction L, a width along a lateral direction A, and a thickness along the transverse direction T, wherein the length and width are greater than the thickness. In alternative embodiments, the second substrate surface 106 need not be parallel to the first substrate surface 104. For example, the second substrate surface 106 can be corrugated.

The packaging material 100 can optionally include a second substrate 152. The second substrate 152 can be spaced from the substrate 102 along the transverse direction T such that the insulation members 108 are disposed between the substrate 102 and the second substrate 152. The second substrate 152 can have a first substrate surface 154 and a second substrate surface 156, opposite the first substrate surface 154 along a transverse direction T. In some embodiments, the insulation members 108 can be adhered to both the substrate 102 and the second substrate 152. In other embodiments, the insulation members 108 can be adhered to only one of the substrate 102 and the second substrate 152. The first substrate surfaces 104 and 154 of the substrate 102 and the second substrate 152 can face one another. The substrate 102 and the second substrate 152 can optionally be attached to one another by an adhesive 150 at one or more edges of the packaging material 100. The second substrate 152 can be devoid of insulation members as shown. In alternative embodiments (not shown), the first surface 154 of the second substrate 152 can have a plurality of insulation members 108 adhered thereto in a manner similar to that discussed herein with respect to the substrate 102.

Similar to substrate 102, the second substrate 152 can be formed from a flexible and/or bendable material such as sheet of paper, cardboard, plastic, or any other suitable flexible and/or bendable packaging material. In some embodiments, as shown, the second substrate 152 can have a planar configuration wherein the first and second substrate surfaces 154 and 156 are parallel to one another. Further, the second substrate 152 can have a length along the longitudinal direction L, a width along the lateral direction A, and a thickness along the transverse direction T, wherein the length and width are greater than the thickness. In alternative embodiments, the second substrate surface 156 need not be parallel to the first substrate surface 154. For example, the second substrate surface 156 can be corrugated.

Turning briefly to FIGS. 9 to 11, each insulation member 108 comprises an insulation material having a plurality of expandable microspheres 112. The microspheres 112 can be microspheres manufactured by Akzo Nobel under the name Expancel or other name, or by another manufacturer. The microspheres 112 can be dispersed in a binder material 113 such as a water-soluble and/or water-based adhesive so as to form a microsphere adhesive that is configured to adhere the insulation members 108 to the substrate 102. As used herein, the term “microsphere adhesive” refers to a material that includes microspheres that are expandable or have expanded in response to exposure to an energy source. Examples of microsphere adhesives include AQUENCE ENV 4200X from Henkel AG & Company, KGaA, such as AQUENCE ENV 42000 and AQUENCE ENV 42001 MFA, which expand upon exposure to convection and microwave heating, respectively.

Each microsphere 112 comprises an outer shell 114. In at least some embodiments, the outer shell 114 is a thermoplastic shell. The outer shell 114 can have a substantially spherical outer surface 116 and a substantially spherical inner surface 118, opposite the substantially spherical outer surface 116. The outer surface 116 of each microsphere 112 has an un-activated outer diameter d₁ in the un-activated state (a), and an activated outer diameter d₂ in the activated state (b). The activated diameter d₂ is greater than the un-activated diameter d₁. In some embodiments, the un-activated diameter d₁ can range from about 5 microns to about 20 microns, and the activated diameter d₂ can range from about 35 microns to about 60 microns. Further, in some such embodiments, the un-activated diameter d₁ can range from about 10 microns to about 15 microns, and the activated diameter d₂ can range from about 40 microns to about 50 microns.

The outer shell 114 of each microsphere 112 also has an un-activated thickness t₁ from the outer surface 116 to the inner surface 118 in the un-activated state (a) and an activated thickness t₂ from the outer surface 116 to the inner surface 118 in the activated state (b). The un-activated thickness t₁ is greater than the activated thickness t₂. Thus, as each microsphere 112 expands, the thickness of the outer shell 114 of the microsphere 112 decreases. The inner surface 118 of each microsphere 112 defines a void 120. In at least some embodiments, each void 120 can be filled with a hydrocarbon 122. As energy such as heat is applied to each microsphere 112, the hydrocarbon 122 in the microsphere 112 expands thereby causing the microsphere 112 to expand. It will be understood that various types of heating, such as (without limitation) convection heating, microwave heating, and RF heating, may be applied to cause the microspheres 112 to expand. Further, other types of energy such as (without limitation) pressure, ultrasound, ultra-violet rays, x-rays, or a chemical reaction may be applied to cause the microspheres 112 to expand.

When expanded, the insulation members 108 can define a plurality of gas pockets 124 generated by the expanded microspheres 112. The gas pockets 124 can be defined in the voids 120 of the microspheres 112 after the hydrocarbon 122 burns off or passes through the shell 114. In at least some embodiments, gas pockets 124 can additionally or alternatively be defined between microspheres 112. Gas within the gas pockets 124 functions as an insulator. The expanded insulation members 108 can have an R value (unit of thermal resistance) similar to Styrofoam, normalized by thickness. Additionally, when expanded, the insulation members 108 can have an elastic property that can provide impact resistance. In fact, the insulation members 108 can have a soft, puffy like structure after expansion. The insulation members 108 can have approximately 45%, or up to as much as approximately 75%, greater impact resistance than a bubble wrap of equivalent thickness. Using a water-based and/or water-soluble adhesive enables the microspheres 112 to be easily removed from the substrate 102 to during the recycling process. Repulpability and recycling studies confirm that bags made from microsphere adhesives can have a 91.2% fiber recovery rate, compared to a recovery rate of 92.9% for corrugate, and well exceeding the 80% yield rate criteria provided by the Fibre Box Association (FBA). Depending on the amount of microsphere adhesive, the recovery rate can be greater than or less than 91.2%. Additionally, microsphere adhesives are certified as Direct Food Contact Safe per the Federal Drug Administration (FDA) regulations, and therefore can be used in food packaging applications.

Referring back to FIGS. 1 to 4, each un-activated insulation member 108 has a body 125 that is adhered to the first substrate surface 104. At least a portion, up to an entirety, of each body 125 can be adhered to the first substrate surface 104. In some embodiments, each body 125 can have an outer perimeter that is adhered to the first substrate surface 104. Each un-activated insulation member 108 can be implemented as a strip as shown. For example, each un-activated insulation member 108 can have a rectangular shape in a plane that is parallel to the first substrate surface 104. Thus, each un-activated insulation member 108 can have a pair of sides 126 that oppose one another, and a pair of ends 128 that oppose one another. Each side 126 can have an overall length L₁, and each end 128 can have an overall width W₁. The overall length L₁ can be greater than the overall width W₁ such that each un-activated insulation member 108 is elongate from one of its ends 128 to the other of its ends 128. Further, each un-activated insulation member 108 can have a top surface 130 opposite the substrate 102. Each top surface 130 can extend between a corresponding pair of sides 126 and between a corresponding pair of ends 128. Each un-activated insulation member 108 can have an overall height H₁ from the first substrate surface 104 to the top surface 130. The overall height H₁ can be less than the overall width W₁ and overall length L₁. It will be understood that, in alternative embodiments, each un-activated insulation member 108 can be implemented to have a shape other than a rectangle in a plane that is parallel to the first substrate surface 104, such as a square, a triangle, a circle, an oval, or any other suitable shape.

The un-activated insulation members 108 can include a plurality of longitudinally-elongate bodies 132 that are elongate along the longitudinal direction L. Further, the un-activated insulation members 108 can include a plurality of laterally-elongate bodies 134 that are elongate along the lateral direction A. The longitudinally-elongate bodies 132 can arranged in a plurality of rows 136 of the longitudinally-elongate bodies 132. In each such row 136, the longitudinally-elongate bodies 132 can be aligned in a side-by-side manner along the lateral direction A with a gap 110 between adjacent ones of the longitudinally-elongate bodies 132. Similarly, the plurality of laterally-elongate bodies 134 can be arranged in a plurality of rows 138 of the laterally-elongate bodies 134. In each such row 138, the plurality of laterally-elongate bodies 134 can be aligned in an end-to-end manner along the lateral direction A with a gap 110 between adjacent ones of the laterally-elongate bodies 134.

Adjacent rows 136 of the longitudinally-elongate bodies 132 can be separated by a row 138 of laterally-elongate bodies 134. Similarly, adjacent rows 138 of the laterally-elongate bodies 134 can be separated by a row 136 of longitudinally-elongate bodies 132. Thus, the insulation members 108 can be arranged along the longitudinal direction L in the following repeating pattern: longitudinally-elongate body 132, laterally-elongate body 134, longitudinally-elongate body 132, laterally-elongate body 134, and so on. Each laterally-elongate body 134 can be aligned along the longitudinal direction L with a pair of the longitudinally-elongate bodies 132 in an adjacent row. It will be understood that, in alternative embodiments, the un-activated insulation members 108 can be arranged in another suitable pattern other than that shown.

Turning now to FIGS. 5 to 8, in the activated state, the plurality of insulation members 108 each have a plurality of expanded microspheres 112 (see FIGS. 9 to 11) activated by energy such as heat. Each activated insulation member 108 comprises a body 125 that is adhered to the substrate surface 104. Further, each activated insulation member 108 has at least one extension 140 that extends from an outer perimeter of the body 125. Each extension 140 has a free end 142 that is free from attachment to the substrate surface 104. The bodies 125 are arranged on the substrate 102 in a pattern such that the bodies 125 are spaced apart from one another by gaps 110 as discussed above. Further, the extensions 140 extend from their respective bodies 125 towards one another so as to at least partially fill in the gaps 110.

As the packaging material 100 is activated, each insulation member 108 expands such that at least one extension 140 extends out from the perimeter of its body 125. The at least one extension 140 can extend outwardly towards an adjacent insulation member 108 so as to fill a gap 110 between the insulation member 108 and an adjacent insulation member 108. Further, each extension 140 can extend outwardly along at least one of the longitudinal direction L and the lateral direction A. For example, each extension 140 can extend from the ends 128 of the body 125 of its insulation member 108 along the longitudinal direction L, and can extend outwardly from the sides 126 of its insulation member 108 along the lateral direction A. In some instances, a single extension 140 can extend outwardly from an entirety of the perimeter of the body 125 of its insulation member 108. In other instances, separate extensions 140 may extend outwardly along the perimeter. It will be understood that the manner in which each insulation member 108 expands may vary based on its chemical composition and location relative to the heating or energy source.

Each extension 140 has a free end 142 and an attached end 144 opposite the free end 142. The attached end 144 is attached to the body 125 of its insulation member 108. The free end 142 is free from attachment to the substrate 102. In some embodiments, the insulation members 108 can be spaced from one another such that, as the insulation members 108 expand towards one another, the free ends 142 contact one another. This contact can result in the free ends 142 moving or flaring transversely away from the substrate 102. For at least some of the insulation members 108, such as those surrounded by other insulation members 108, this transverse movement can result in the insulation members 108 having a shape that is similar to the haul of a boat as shown in FIG. 8. The inventor surmises that heat transfer between the insulation members 108 can additionally or alternatively cause the free ends 142 to move or flare transversely away from the substrate 102. For example, the heat may create a vortex of gases that push the free ends 142 away from the substrate 102.

Contact between the free ends 142 can reduce permeability of air through the packaging material 100 and can increase thermal resistance of the packaging material 100 when compared to the packaging material in its un-activated state. Further, since the insulation members 108 expand towards one another, the insulation members 108 can be spaced apart from one another as shown in FIGS. 1 to 3, as opposed to coating the entire first substrate surface 104 with the insulation material. Thus, the packaging material 100 can use less insulation material than would be needed to coat the entire first substrate surface 104. Using less insulation material can in turn reduce costs and improve chances for curbside recyclability.

With reference to FIG. 12, the packaging material 100 can be implemented in a multi-layer package such as a paper bag 200 or box (not shown). The substrate 102 can form the inner layer of the paper bag, and the second substrate 152 can form the outer layer of the paper bag. The second substrate surface 106 of the substrate 102 can define a void 202 inside the bag 200 in which items are received. In some embodiments, the second substrate surface 106 can be coated with a water resistant material to provide moisture resistance from condensation from cold food products or icepacks carried inside the bag 200. The second substrate surface 156 of the second substrate 152 can define the outer surface of the bag 200. The insulation members 180 between the substrate 102 and the second substrate 152 can be activated before the bag 200 is formed or after the bag 200 is formed. In some situations, activating the insulation members 180 after the bag 200 is formed may be preferable as the packaging material 100 occupies less space when it is in the un-activated (un-expanded) state than when it is in the activated (expanded) state. Thus, embodiments of the disclosure can include un-activated packaging material, activated packaging material, packages formed from un-activated packaging material, and packages formed from activated packaging material.

It should be noted that the illustrations and descriptions of the embodiments shown in the figures are for exemplary purposes only, and should not be construed limiting the disclosure. One skilled in the art will appreciate that the present disclosure contemplates various embodiments. Additionally, it should be understood that the concepts described above with the above-described embodiments may be employed alone or in combination with any of the other embodiments described above. It should further be appreciated that the various alternative embodiments described above with respect to one illustrated embodiment can apply to all embodiments as described herein, unless otherwise indicated.

Unless explicitly stated otherwise, each numerical value and range should be interpreted as being approximate as if the word “about” or “approximately” preceded the value or range.

It should be understood that the steps of exemplary methods set forth herein are not necessarily required to be performed in the order described, and the order of the steps of such methods should be understood to be merely exemplary. Likewise, additional steps may be included in such methods, and certain steps may be omitted or combined, in methods consistent with various embodiments.

Although the elements in the following method claims, if any, are recited in a particular sequence with corresponding labeling, unless the claim recitations otherwise imply a particular sequence for implementing some or all of those elements, those elements are not necessarily intended to be limited to being implemented in that particular sequence. 

What is claimed:
 1. A packaging material, comprising: a substrate having a surface; and a plurality of insulation members, each having a body that is adhered to the surface, and each comprising a plurality of expandable microspheres, wherein the bodies are arranged on the surface in a pattern such that the bodies are spaced apart from one another by gaps, and the expandable microspheres are configured to expand in response to application of energy such that the insulation members expand towards one another to at least partially fill in the gaps.
 2. The packaging material of claim 1, wherein the substrate comprises paper.
 3. The packaging material of claim 1, wherein the bodies include a plurality of longitudinally-elongate bodies that are elongate along a longitudinal direction, the longitudinally-elongate bodies being arranged in a plurality of first rows, wherein the longitudinally-elongate bodies in each first row are aligned in a side-by-side manner along a lateral direction, perpendicular to the longitudinal direction, with a gap between adjacent ones of the longitudinally-elongate bodies.
 4. The packaging material of claim 3, wherein the bodies include a plurality of laterally-elongate bodies that are elongate along the lateral direction, the plurality of laterally-elongate bodies being arranged in a plurality of second rows, wherein the laterally-elongate bodies in each second row are aligned in an end-to-end manner along the lateral direction with a gap between adjacent ones of the laterally-elongate bodies.
 5. The packaging material of claim 4, wherein adjacent first rows of the longitudinally-elongate bodies are separated by a second row of laterally-elongate bodies.
 6. The packaging material of claim 4, wherein adjacent second rows of the laterally-elongate bodies are separated by a first row of longitudinally-elongate bodies.
 7. The packaging material of claim 4, wherein each laterally-elongate body in a second row is aligned along the longitudinal direction with a pair of the longitudinally-elongate bodies in an adjacent first row.
 8. The packaging material of claim 1, wherein each insulation member is configured such that, upon application of energy, at least one extension extends out from a perimeter of its respective body towards an adjacent insulation member.
 9. The packaging material of claim 8, wherein the at least one extension has a free end that is free from attachment to the substrate.
 10. The packaging material of claim 9, wherein the insulation members are configured such that, as the insulation members expand towards one another, the free ends of the insulation members contact one another and move away from the substrate.
 11. A packaging material, comprising: a substrate having a surface; and a plurality of insulation members, each having a plurality of expanded microspheres activated by energy, each insulation member comprising a body that is adhered to the surface, and having at least one extension that extends from an outer perimeter of the body, each extension having a free end that is free from attachment to the surface, wherein the bodies are arranged on the substrate in a pattern such that the bodies are spaced apart from one another by gaps and the extensions extend from their respective bodies towards one another so as to at least partially fill in the gaps.
 12. The packaging material of claim 11, wherein the substrate comprises paper.
 13. The packaging material of claim 11, wherein the bodies include a plurality of longitudinally-elongate bodies that are elongate along a longitudinal direction, the longitudinally-elongate bodies being arranged in a plurality of first rows, wherein the longitudinally-elongate bodies in each first row are aligned in a side-by-side manner along a lateral direction, perpendicular to the longitudinal direction, with a gap between adjacent ones of the longitudinally-elongate bodies.
 14. The packaging material of claim 13, wherein the bodies include a plurality of laterally-elongate bodies that are elongate along the lateral direction, the plurality of laterally-elongate bodies being arranged in a plurality of second rows, wherein the laterally-elongate bodies in each second row are aligned in an end-to-end manner along the lateral direction with a gap between adjacent ones of the laterally-elongate bodies.
 15. The packaging material of claim 14, wherein adjacent first rows of the longitudinally-elongate bodies are separated by a second row of laterally-elongate bodies.
 16. The packaging material of claim 14, wherein adjacent second rows of the laterally-elongate bodies are separated by a first row of longitudinally-elongate bodies.
 17. The packaging material of claim 14, wherein each laterally-elongate body in a second row is aligned along the longitudinal direction with a pair of the longitudinally-elongate bodies in an adjacent first row.
 18. The packaging material of claim 11, wherein the free ends of the insulation members are flared transversely away from the substrate.
 19. A method of forming a packaging material, the method comprising: applying energy a plurality of insulation members, each having a body that is adhered to a surface of a substrate, the bodies being arranged on the surface in a pattern such that the bodies are spaced apart from one another by gaps, wherein applying the energy causes a plurality of expandable microspheres of each insulation member to expand such that the insulation members expand towards one another to at least partially fill in the gaps.
 20. The method of claim 19, wherein the applying step comprises causing free ends of the insulation members to contact one another and move transversely away from the substrate. 